NEWS LETTER REV 1

BIMONTHLY

NEWSLETTER ON

PROCESS

SAFETY SAFEXCELLENCECE

Significant Accidents in

August - 2020

Beirut Explosion

The catastrophic explosion at Beirut

port on 4th August 2020 that has so

far killed at least 100+ people and

injured around 4,000+, with an

unknown number feared trapped

under rubble was, according to the

government of Lebanon, caused by

over 2,700 tonnes of ammonium

nitrate kept in storage for over six

years.

https://www.bbc.com/news/explainers-53664064

Massive Fire Breaks Out At Textile Factory In Gujarat's Sanand

The massive blaze raged-on

uncontrolled for more than eight

hours- destroying the facility, which

manufactured products including

sanitary napkins, diapers etc.

https://www.thehindubusinessline.com/news/major-blaze-breaks-out-at-unicharms-sanand-facility/article31904242.ece

Editorial The Center of Excellence (CoE) in industrial

safety is established at SRICT-Ankleshwar, by

the congruous collaboration of UPL Ltd. and

Gexcon, Norway. The CoE is bracing up to

accept challenges for making industrial work-

field a safer place, protecting human lives,

environment and properties. Zero accident in

industries is a reachable target when attitude

of caring meets sharing of relevant knowledge.

SAFEXCELLENCE is reaching you at a

crucial time, when accidents in process plant

are on the rise after the lockdown. The

newsletter has an aim of not only sharing the

occurrences of industrial catastrophes, which

fill us with fear and tears but would more like

to tell you to focusing care for peers and pare

their perils, being a seminal stake-holder of the

society.

The Safety Newsletter also attempts to bring in

experts from industry, government offices, and

academia to share their valuable views on

safety aspects, on one platform, aiming to

reduce risk and hazards in chemical

industries.

We are pleased to present to you the first issue

of SAFEXCELLENCE. Your views and

responses are welcome. Please mail it to

[email protected]

THIS ISSUE Editorial P.1

Best Wishes On Inaugural Issue P.2, P.3

Webinar – Curtain Raiser P.4

CoE Activities P.5

Evaluation Of Accidents Based On PSM Elements P.6

CoE Way Forward P.7

Specialized Safety Assistance To Industries P.8

IS S U E

A U G U S T 2 0 2 0

01

Newsletter Issue: 1 August 2020 Page No: 1

Massive Fire Breaks Out At Chemical Factory In Gujarat's Valsad

Massive fire was reported at a pharmaceutical company situated in the third phase of Vapi GIDC in Valsad district due to the blast in the chemical solvent drums stored in the manufacturing unit on 8th August 2020.

https://timesofindia.indiatimes.com/city/surat/surat-major-fire-breaks-out-in-a-pharmaceutical-company-no-casualty-reported/articleshow/77430565.cms

One Killed, Three Hurt In Oxygen Cylinder Blast In Udhana In Industrial Area

One person was killed, and three others injured after a cylinder exploded at the oxygen refilling unit in the city’s Udhana area on 11th August 2020. The unit refills oxygen cylinder used by industrial units and hospitals. The explosion occurred due to heavy pressure generated during refilling of cylinders.

https://timesofindia.indiatimes.com/city/surat/surat-one-killed-three-hurt-in-oxygen-cylinder-blast-in-udhana-industrial-area/articleshow/77483399.cms

Chemical Factory Explosion Kills Six In China

Safexcellence

Best Wishes On CoE Inaugural Issue


Mr. Vikram Shroff (Director, UPL Ltd)

Mr. Ashok Panjwani (Executive Director, UPL Ltd)

"The Center of Excellence (CoE) in Industrial Safety established at

SRICT by UPL Ltd in collaboration with Gexcon, Norway is a special

endeavour of UPL in the interest of the global technical community.

The hazards on the shop floor can only be minimised/avoided

through constructive application of the latest knowledge and

appropriate use of technology. The CoE, in due course of time, will

strut its stuff. I am sure Chemical Industry will welcome

"SAFEXCELLENCE", the e-newsletter of the CoE, and would join

hands to Make India Safer while Make in India. My Best wishes to

SAFEXCELLENCE."

“The Center of Excellence (CoE) in Industrial Safety started at SRICT with

the support of UPL Ltd and Gexcon as knowledge partner is an example

of confluence of scientific knowledge and its application for human

safety, social responsibility of Industry, and a direct service of an

academic institute towards industry and the nation both. As a humble

Vice Chairman of an academic institute (SRICT), and Executive Director

of UPL Limited & Past District Governor of Rotary International,

Dist.3060, I send my best wishes to SAFEXCELLENCE – the e-newsletter

of CoE.”

Dr. J. P. Gupta (Chairman EAC-II MOEF&CC Govt. of India)

“This is a broader objective that the country as a whole and other

corporates should subscribe to. We should look at developing

guidelines in this direction for both corporates including MSME’s

and engineering institutes and should target to generate at least

100,000 Process Safety specialists in the next 5 years.”

“The visionary whose inspiration led to birth of this centre of

excellence at SRICT.”


Dr. Jan Roar Bakke (Executive VP, Gexcon AS, Norway)

Mr. Rajendra Narkhede (Country Manager, Gexcon India)

Mr. V V Surya Rau (Chairman-Gexcon Advisory Board & Advisor, RIL)

“It is with great pleasure I endorse the first issue of SAFEXCELLENCE,

the e-newsletter of the newly formed Center of Excellence in Industrial

Safety. Gexcon is proud to be a key participant in this great endeavour,

together with SRICT and UPL, and we will do our utmost to make it a

success, to contribute to a safer India.”

“I am extremely pleased with and sincerely appreciate the coming together

of Indian International Company UPL/Rotary SRICT collaboration with

internationally reputed Organization in establishing the pace

setting academic programs for enhancing the Process Safety

Risk Management in India.”

“Gexcon is committed to bring education and research in Process

Safety in India. I am sure these issues will be important

aspects in Industry 4.0 initiatives. The SRICT CoE Newsletter will play

important role to share CoE progress and recent developments. The

most important initiative will be to review recent accidents and

identify areas of improvement at local, state and national level.”

Safexcellence

Prof. G.D. Yadav (Former Vice Chancellor ICT, Mumbai)

“UPL has floated a very apt thought of having a process safety

risk management system at the design and conceptualization

stage of manufacturing. The system, once implemented will see a

quantum jump in reduction of chemical industry incidents that we

very often hear today and change the perception of this

industries.”

(Contd. From Page 3)

An explosion killed six workers at a chemical plant in Xintao City, China on August 3. The blast in central China’s Hubei province happened in a workshop of an organic silicon company and injured four people in addition to the six people killed.

http://www.hazardexonthenet.net/article/180076/Chemical-factory-explosion-kills-six-in-China.aspx

Ammonia Gas Leak At Private Dairy Unit In Andhra's Chittoor Injures 20 Women

On 21st August More than 15-25 people were rushed to a hospital on Thursday evening after a gas leakage was reported at a dairy plant located at Bandapalli village of Andhra Pradesh's Chittoor district.

https://www.msn.com/en-in/news/newsindia/ammonia-gas-leak-at-private-dairy-unit-in-andhras-chittoor-injures-20-women/ar-BB18cOiF?li=AAggbRN

Two Workers Asphyxiated To Death At Jajmau Tannery

Two civic workers at a leather unit in Jajmau died of asphyxiated while cleaning a septic tank inside its premises on 23rd August 2020. The management of Supreme Tannery on outskirts of the city had engaged a team of four civic workers to clean the tank. Moments after entering the tank two of the workers fell unconscious on inhaling the toxic fumes.

http://timesofindia.indiatimes.com/articleshow/77710396.cms?utm_source=contentofinterest&utm_medium=text&utm_campaign=cppst

Make India Safer while Make in India

CURTAIN RAISER

Mr. Gary Pilkington

(Principal Process Safety Engineer

GEXCON UK LTD)

Day 1

31st July

Hazardous Chemicals

Management & PSM

Day 2

1st August

Ensuring Process Safety in

Design- Basic Requirement

Day 3

13st August

Managing Hazardous Chemical Reactions

Day 4

14st August

Emergency

Preparedness and Response

Process Safety Management Training Program For DISH Officials by UK Trainer

Gexcon has developed first of its kind Centre of Excellence (CoE)

in India at Shroff S. R. Rotary Institute of Chemical Technology

(SRICT) Ankleshwar, our partner educational institute . Under the

CoE, Gexcon AS will support and coordinate with University of

Bergen in Norway and develop higher education and research

programs in Safety in India. This is expected to open a new domain

constituting trained experts in risk assessment and performing

consequence analysis using advanced techniques, in the field of

process safety.

Process Safety and Risk Management are some of the key drivers,

set up by Government of India, to achieve five trillion economy goal.

Fortunately, this brings back the focus of academia, industries,

policy makers and regulators on this important aspect. Globally it is

proven that the learning from accidents helps in prevention of same

or similar type of incidents, and also helps in designing safer plants

and improving effective consequences mitigation systems.

Incidentally, there is no centralized system, like CSB (USA), which

documents, investigates and educates about chemical accidents in

India to which SRICT is trying to provide alternative at national

level. Several Universities/research organizations, abroad, have

taken initiatives to develop higher education and research in

prevention of accidents.

As a “Curtain Raiser” to the CoE on process safety, a well attended

webinar on “MAKE INDIA SAFER, WHILE MAKE IN INDIA” was

organised. Eminent professionals presented their papers on the

event at Shroff S.R. Institute of Chemical Technology (SRICT).

For Further Information Contact Us:

Mr. Rajendra Narkhede (Country Manager, Gexcon India)

[email protected]

+91 9820174344


TRAINING PROGRAM FOR MEMBERS OF CoE BY

GEXCON-INDIA FLACS TRAINER

Introduction:The course covers the

standard modules in FLACS, such as

geometry import and generation, gas

dispersion, explosion and fire, as well as liquid

pool spread. It also comprises presentations

on validations, explosion mitigation, QA, and

probabilistic risk analysis (Including a FLACS-

Risk demonstration). This course combines

theory, demonstrations, and practical

exercises with FLACS software. Therefore,

participants will be required to practice and

apply their new knowledge through hands-on

exercises. The training program envelops

presentations and hands-on training for more

than half the time.

Course Objectives: The attendees will gain

an understanding on the following topics:

Physical models, applications areas and

functionality of FLACS

FLACS workflow: Preprocessing,

processing and postprocessing

Guidelines for setting up FLACS

simulations

Quality assurance of FLACS scenarios

and results

Proficiency in using FLACS for standard

applications in their projects

SAFEXCELLENCE

Gexcon Industrial

safety and risk assessment

Software Flame Acceleration Simulator (FLACS) is

a commercial Computational Fluid

Dynamics (CFD) code developed and

marketed by Global Explosion

Consultants (GexCon), based in Bergen,

Norway. The software has been

developed to model the dispersion and

combustion of flammable liquids, gases

and dust clouds in open and bounded

geometries.

FLACS (Flame Acceleration Simulator) is

the industry standard for CFD

(Computational Fluid Dynamics)

explosion modelling and a

comprehensive tool for technical safety

issues related flammable and toxic

releases.

https://www.gexcon.com/in/products-services/flacs-software/

Beirut Explosion 3D CFD Simulation By GEXCON (FLACS)

Gexcon is a first in the world who

developed/resulted blast wave from

ammonium nitrate explosion in FLACS

3D CFD tool.

https://www.youtube.com/watch?v=hlPjKc4BaHo


CoE Activities

Members of CoE, SRICT

(From Left to right)

Dr. Omprakash Mahadwad -Professor, SRICT(Coordinator)

Dr. Kalpana Rewatkar Yeole – Trainer, Research Scientist, GEXCON India

Dr. Ravindra Kanawade – Asso. Professor, SRICT

Mr. Amol Lakare – Process Safety Manager, UPL Ltd.

Dr. Alok Gautam – Professor, SRICT

Dr. Shina Gautam – Asso. Professor, SRICT

Mr. Govind Keshavrao Patil – Trainer, Process Safety Engineer GEXCON India

Coordinator of CoE, UPL L td.

Mr. Piyush Shah

(Head-Health & Safety, UPL Ltd.)

Incidents continue to occur in various industries that use highly hazardous chemicals which may be

toxic, reactive, flammable, or explosive, or may exhibit a combination of these properties.

Regardless of the industry that uses these highly hazardous chemicals, there is a potential for an

accidental release any time they are not properly controlled. This, in turn, creates the possibility of

disaster.

There are many renowned process safety management systems available worldwide. These

systems have most of the safety elements in common, with little variations in number and titles.

SRICT CoE has selected 17 process safety elements and based on these, shall attempt to analyze

disaster for the probable cause/s. SAFEXCELLENCE team will collate data of major accidents took

place during the month and will publish the missing process safety element/s in the news letter.

This baby step taken by SRICT CoE for establishing a data bank of major accidents and subsequent

analysis will immensely help our industrial partners to take informed decisions on process safety

and achieve zero harm to people, environment and assets and contribute to the larger goal of five

trillion economy of our nation.

MISSING PSM ELEMENTS WHICH CAUSED THE ACCIDENT

AUGUST 2020


ELEMENTS OF PROCESS SAFETY MANAGEMENT

SAFEXCELLENCE

1 Killed, 4 Injured In Tarapur Chemical Factory

One person died and at least 4 workers sustained serious injuries in an explosion in an organic chemical factory in Tarapur chemical zone in Palghar district on 17th August 2020. The blast was believed to have occurred in reactor during a process, shattering the window panes of adjacent pharma company too.

http://timesofindia.indiatimes.com/articleshow/77595847.cms?utm_source=contentofinterest&utm_medium=text&utm_campaign=cppst

Yashashvi Rasayan Pvt Ltd -Dahej Fire Incident

Once again fire broke out in Yashashvi Rasayan Chemical company of Dahej on 22nd August 2020. Around 35-40 workers sustained burn injuries after the boiler had exploded on 3rd June 2020 in the same plant. This time there has been no casualty and the fire department controlled the fire within few minutes. Fire broke out during debris removal operation.

https://www.livemint.com/news/india/massive-blast-in-gujarat-chemical-factory-around-40-workers-injured-11591181036204.html

SAFEXCELLENCE

CoE Way Forward Development Of Faculties In Process Safety.

Gexcon Certified Courses

Dust Explosion Hazards Course Gas Explosion Hazards Course Explosion Science Course Process Safety Management Courses Electrostatic Hazards Course Hazardous Area Classification Course Mechanical Equipment to be Used in Flammable Atmospheres

Development Of Master Program In Process Safety With University Of Bergen (Norway)

Development Of Industry Sponsored Research Projects In Process Safety

Maintaining Data Base Of Accidents With Analysis

Assisting Industries In Implementation Of Process Safety Management

High Value Learning Audits Of Accidents And Recommendations

Development Of Virtual Reality (VR) Training Programs

Development Of Laboratory For Explosivity Testing

Participation In Safety Standards Development Process


Positive things towards

industrial process safety

in INDIA - August – 2020

Chennai Finally Swung Into Action

After the Beirut explosion, authorities in Chennai finally swung into action. Almost 700 tonnes of ammonium nitrate reportedly transported to Hyderabad. Around 10 containers were transported and security personnel accompanied the trucks. The consignment worth Rs 1.8 crore was kept in a Chennai container freight station.

https://www.thehindu.com/news/cities/Hyderabad/ammonium-nitrate-from-chennai-ferried-to-hyderabad-after-firm-buys-them-in-e-auction/article32313947.ece

India Issues Safety Rules On Restarting Factories After Gas Leak

India has released safety guidelines for restarting manufacturing industries as it partially eases the world’s most expansive pandemic lock down and tries to avoid further incidents after a gas leak last week. https://www.bloombergquint.com/business/india-issues-safety-rules-on-restarting-factories-after-gas-leak


CoE Newsletter Editorial Board

SAFEXCELLENCE

PSM Consulting Assignments To Medium/Large Chemical Companies

PSM Training Programs To Medium/Large Chemical Companies

Preparation Of High-Class Training Videos, Using Combination Of FLACS Software, Animations And

Virtual Reality, For Company Specific Risk Assessment

Research Projects To Lead Master/Ph. D. For Sponsored Candidates From Companies/Owners

Laboratory Specialized Safety Testing Services For Industry Organizations

Full Scale Fire/Explosion Tests For Industry Organizations/Governments/Vendors

SPECIALIZED SAFETY ASSISTANCE TO INDUSTRIES

CoE Newsletter Editorial Board

Editor In Chief Editor Dr. Shrikant J. Wagh (Principal, SRICT) Dr. Omprkash Mahadwad (Professor - SRICT)

(Contact :+918975033066) Mr. Prakash Dandwate (General Manager, Gexcon India) Dr. Kalpana Yeole (Research Scientist, Gexcon India)

Conveners, Content Editor And Graphic Designer

Mr. Govind Keshavrao Patil Ms. Monika Patel (Process Safety Engineer, Gexcon India) (Assistant Professor, SRICT)

Executive Student Members

Juily Pawaday Ankita Shah Richa Patel (Chemical Engineering) (Environment Science &Technology) (Chemical Technology)

For More information Contact Us

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Documents

NEWS LETTER REV 1